EP0595287B1 - Process for the production of semi-finished corner units of laminate - Google Patents

Abstract

For the production of a semi-finished angle profile from composite panels, which is distinguished by high strength combined with high thermal and acoustic insulating properties and is simple to produce, a composite panel with a V-shaped groove is provided. The composite panel consists of a foam core or core elements on a layer of wool, fibres or the like alone or provided with at least one layer of extruded foam. On one of the outsides there is arranged at least one woven or non-woven glass fibre fabric (102) which is disposed in a cured layer of mortar (103). By means of an activatable stop (128), the parts of the composite panel are folded upwards from the plane, so that a composite-panel strip (109) is opposed to another composite panel strip (119) at right angles. With the aid of an orifice (111), liquid hot-melt adhesive is introduced into the space between the insides of the groove, so that, after it has hardened and cooled, an L-shaped semi-finished angle profile is produced. <IMAGE>

Description

The invention relates to a process for producing semi-finished products from composite panels and the use of known and new composite panels when using such a method.

It is known to produce an angle semi-finished product from composite panels. For this purpose, composite panels are used which have a foam core, on the at least one flat side of which a glass fiber fabric or fleece is applied, which is embedded in a solidifying mortar. However, in order to be able to connect two composite panels with one another, either the glass fiber fabric or nonwoven must be removed or a composite point is created which has an unclean appearance. In addition, the composite panel has an edge area that is not reinforced, so that the outer surfaces have a different appearance and also different adhesion properties.

From DE 31 36 935 C1 a web or plate made of mineral wool is known. Here mineral fibers are layered side by side and covered with a film. A plaster can be applied to this outer surface. The disadvantage is that this plate is too elastic and therefore too unstable and is only suitable for stripping roofs or walls.

Furthermore, DE 34 44 881 C2 discloses a sound-absorbing building wall or ceiling structure in which mineral fiber boards and a layer of prefabricated elements adhering to the sides made of a mortar matrix are attached to a load-bearing structure with a glass fiber reinforcement. The disadvantage is that the mineral fiber boards consist only of mineral fibers and are therefore too unstable. The reinforced mortar layer prevents the mineral fiber board from falling apart, so that the strength has to be created with great effort by a load-bearing construction.

The invention has for its object to provide a method for producing an angle semi-finished product from composite panels, which is characterized by high manufacturing capacity and flawless products. It should be possible to use both the core as a foam core and the core of one or more layers of fibers, including wool, spheres, chips, strips, sections or the like made of organic substances and / or inorganic substances or a first layer of extruder foam, one To produce a layer of fibers, wool, balls, chips, strips, cuts or the like from organic and / or inorganic substances and a second layer of extruded foam.

• a) rechteckige Verbundplattenabschnitte der Breite ( $\text{B1 + B2 + ...}$
  
  ) werden mittels eines relativ zur Längserstreckung des Verbundplattenabschnittes beweglichen kombinierten Fräs- und Schneidwerkzeuges in Doppelstreifen zu Breiten (B1, B2, ...) geschnitten, wobei gleichzeitig in wenigstens einen der Doppelstreifen eine V-förmige Nut eingebracht wird, deren Nuttiefe die Armierung ausspart und wobei zu beiden Seiten der Nut je ein Verbundplattenstreifen entsteht,
• b) anschließendes Durchtrennen (Brechen) des mit der V-förmigen Nut versehenen Doppelstreifens in der Nut unter Beibehaltung einer die Nutspitze überbrückenden Armierung und Aufstellen einer Γ-Konfiguration aus den beiden Plattenstreifen, wobei die Nutinnenseiten Gehrungsflächen werden,
• c) Einbringen eines flüssigen Heißklebers in den Raum zwischen die Nutinnenseiten,
• d) Abkühlenlassen des Klebers und Entnehmen des fertigen Halbzeugs.

The process solves the stated task by the following process steps:

• a) rectangular composite panel sections of width ( $\text{B1 + B2 + ...}$
  
  ) are made into double strips by means of a combined milling and cutting tool that is movable relative to the longitudinal extent of the composite plate section cut to widths (B1, B2, ...), at the same time a V-shaped groove is made in at least one of the double strips, the groove depth of which saves the reinforcement and a composite panel strip is created on both sides of the groove,
• b) then severing (breaking) the double strip provided with the V-shaped groove in the groove while maintaining a reinforcement bridging the groove tip and setting up a Γ configuration from the two plate strips, the inside of the groove becoming miter surfaces,
• c) introducing a liquid hot glue into the space between the inside of the groove,
• d) allowing the adhesive to cool and removing the finished semi-finished product.

DE-A-3901237 describes a method for producing an angle semi-finished product from composite panels. However, the use of mortar-coated slabs is not indicated.

The advantages achieved by the invention consist in particular in that, by introducing a groove exactly into the boundary layer between the core and the outer reinforced mortar layer, there is the possibility of breaking the hardened mortar layer and, after connecting the inner sides of the V-shaped groove, an angular semi-finished product with a consistently reinforced uniform outer surface. Due to the continuous outer reinforced mortar layer, it is possible to either clean it, cover it with tiles, paper it or process it in some other way without the semi-finished product having different external structures.

It is advantageous if a densified layer of fibers, wool, spheres, chips, strips, sections or the like made of organic and / or inorganic substances, for example mineral fibers and / or wool, is used. Rock wool, glass wool and the like are used as mineral fibers. The mineral fibers can either be parallel to each other in be inclined at an angle of 10 - 80 ° to the plane of the board or lie next to and on top of each other like wool. By compressing the fiber layer and / or wool layer, it is possible to produce a core that has an exact dimension.

It is advantageous if the layer of fibers, wool, spheres, chips, strips, sections or the like made of organic and / or inorganic substances, e.g. Mineral fibers, is coated with extruder foam so that the extruder foam with the fibers, wool, spheres, chips, strips, sections or the like from organic and / or inorganic substances prevails. This combines the high strength properties of the hardened extruder foam and the excellent sound and heat insulating properties of the layer. This is further increased by the fact that the fibers / wool and the like mix with the extruder foam, thus ensuring a very intimate connection of all layers.

Due to the simultaneous milling and cutting of the composite panels, several angle witnesses can be produced simultaneously in the area of a feed. By bridging the milled groove tip through the reinforcement, the two composite panel sections remain in contact with one another and can thus be handled more easily. By using a hot glue, the glue can be completed in a short time; Solvent vapors are not generated. This reduces the investment costs in particular.

The two composite panel strips can be connected at any angle; however, they are preferably connected at an angle of 90 °; this means that the V-groove must have an opening angle of 90 °.

In principle, it is possible to convey the composite panel sections relative to the fixed milling and sawing tool or to move the milling and sawing tool relative to the longitudinal extent of the composite panel section. Since the first-mentioned embodiment allows more precise work, it is preferred.

After the material has been applied, the angled semi-finished product blank is preferably blown with cooling air along a conveyor line, so that the blank no longer has to leave the conveyor line until completion.

To set up the angle configuration, a controllable stop is unfolded from the conveyor level.

This stop preferably interacts with a sensing device which, after the composite plate section has passed completely through the milling and sawing device, triggers the stop to be raised.

In order to be able to produce different widths, it is proposed to make the milling and sawing device adjustable over the width of the composite plate section.

It is possible to use the semi-finished product produced in the process according to the invention for the production of tube boxes and closed hollow profiles. The possibility of varying the opening angle in the specified wide range also opens up the possibility of being able to make artificial walls or cladding in geometrically difficult rooms, such as are present in particular in houses, patrician houses and the like which are under monument protection. The second wall in front of the actual, damaged wall made of an angled semi-finished product gives the possibility, on the one hand, of covering the damaged wall and, on the other hand, of supply lines, such as eg. B. drainage, fresh water pipes, power supply lines, telephone lines and the like.

Thanks to the sound and heat insulating properties of the composite panel, it is also possible to safely separate the individual supply lines in accordance with the existing regulations and to hide their existence visually, acoustically and thermally from the visitor to the historical rooms or the occupant of such an object.

Figur 1

einen Verbundplattenabschnitt,

Figur 2

den geschnittenen und eingefrästen Verbundplattenabschnitt,

Figur 3

die in einer Winkelkonfiguration geklappten Streifen,

Figur 4a

einen Verbundplattenabschnitt mit einem Kernelement gemäß Figur 1 in einer schematischen Seitenansicht,

Figur 4b

einen Verbundplattenabschnitt mit einem Schaumfaserkern gemäß Figur 1 in einer schematischen Seitenansicht,

Figur 5a

eine Fertigungslinie zur Herstellung eines Kernelementes für einen Verbundplattenabschnitt gemäß Figur 1 und 4,

Figur 5b

eine weitere Fertigungsmöglichkeit für die Herstellung eines Kernelementes für eine Verbundplatte gemäß Figur 1 und 4 und

Figur 6

eine Fertigungslinie zur Herstellung eines Winkelhalbzeugs aus Verbundplatten gemäß Figur 1, 4a und 4b.

The object of the invention is shown in the drawing. Show it:

Figure 1

a composite panel section,

Figure 2

the cut and milled composite panel section,

Figure 3

the strips folded in an angular configuration,

Figure 4a

2 shows a composite side panel section with a core element according to FIG. 1 in a schematic side view,

Figure 4b

2 shows a schematic side view of a composite panel section with a foam fiber core according to FIG. 1,

Figure 5a

a production line for producing a core element for a composite panel section according to Figures 1 and 4,

Figure 5b

a further manufacturing possibility for the production of a core element for a composite panel according to Figures 1 and 4 and

Figure 6

a production line for producing an angle semi-finished product from composite panels according to Figure 1, 4a and 4b.

A composite panel section 110, which is cut from a larger composite panel, for the production of an angle semi-finished product is shown in FIGS. 1, 4a and 4b. The composite plate or the composite plate section has a core element 101 made of fiber or foam.

The core element 101 can either have only one layer of mineral fibers 122 and / or wool 122 'or a layer of mineral fibers 122 and / or wool 122' which is covered with at least one layer of extruder foam 108 or 121, as shown in FIG. 4a.

In the composite panel 110 shown in FIG. 4b, the foam core 101 'consists of a layer of polystyrene foam 108', or of foam glass, loose or foamed recycling material or the like.

In order to be able to manufacture the core element 101, as shown in FIG. 5a, a roller conveyor 201 with a flat one is used a smooth layer of extruder foam from an extruder foam device 204. After this extruder foam layer 108 has cooled, it is covered with a layer of mineral fibers 122 or wool 122 'from a mineral fiber device 207. It is possible that the mineral fibers 122 and / or wool 122 'are compressed by tapping or rolling. This creates a flat and essentially equally thick layer of mineral fibers 122 and / or wool 122 '. A layer of extruder foam 121 is in turn foamed from a further extruder foam device 209 onto the layer 122 or 122 '. The core element 101 thus finished is fed in plate form through the roller conveyor 201 for further processing.

It is of course also possible, as shown in FIG. 5b, that the mineral fibers 122 and / or wool 122 'are given a preformed height and width by a mineral fiber device 207' in such a way that a substantially smooth, equally high and equally wide core layer is produced Mineral fibers 122 and / or wool 122 '. This core element 101 is already fed to further processing in this form.

If wool-like mineral fibers 122 and / or animal wool 122 'have been used, it is possible for the extruder foam 108 and 121' coming from the extruder foam devices 204 'and 209' from both sides into the outwardly emerging individual fibers 122 and 122 ' this very loose and fibrous structure of mineral fibers 122 and / or wool 122 'penetrates and, depending on their density and strength, creates a core element 101 in which it mixes mineral fibers 122 and / or wool 122' with extruder foam 108 and 121 is coming. After the extruder foam layers 108 and 121 have cooled on a special roller conveyor 201 ', a core element 101 stands for further processing to disposal.

Its further processing can take place continuously or discontinuously, i. H. The production line shown in FIG. 6 directly adjoins the production lines shown in FIGS. 5a and 5b, or these are located at a completely different location in the production site or at a different production location.

The horizontally lying core element 101 is brought up on a driven roller conveyor 201. The core element preferably has a thickness of 5-50 mm. A mortar 103 is placed in a mortar silo some distance from a mortar applicator. A dosing device 205 is connected between the two devices and can be controlled electronically in a graduated manner. The mortar 103, which is in the fluid state in the mortar application device, is applied to the side of the core element 101 to be coated, in a relatively rough distribution in three or four beads. These beads are brought to an approximately the same layer thickness, possibly with a surface structure, by an equalizer 206.

According to the equalizer 206, an endless web of glass fiber fabric or fleece 102 or another material is brought into a practically tension-free state, ie essentially due to its own weight and at the same speed as the transport speed of the core element 101. A supply roll of glass fiber fabric or fleece 102 is located on a supply roll 218 and is guided over a web store 219, as is known per se from textile technology. The web of glass fiber fabric or nonwoven 102 is pressed into the mortar layer 103 by a pressing device 208 and embedded. The excess mortar 103 is stripped off by a scraper 210 and distributed in a layer such that it both embeds and slightly projects over the web 102, so that the web 102 subsequently forms reinforcement in the still moist mortar 103.

The mortar surge 211 forming in front of the scraper 210 forms a lip 212 as a front boundary, which is scanned with the aid of an opto-electronic or capacitive sensor 213. If the lip reaches a position that is too far away from the scraper 210, the sensor signal from the sensor 213 is designed by a data processing system 214 such that the metering device 205 is closed further, so that the amount of mortar 103 flowing out of the container over time decreases. If the lip 212 moves back in the direction of the scraper 210, the EDP signaling device 214 has the metering device 205 opened again and further releases new quantities of mortar 103. After the scraper 210 there is accordingly a uniform mortar layer 103 on the core element 101.

The core element 101 now passes into a cutting station 215, where a knife 215 ', laser beam, belt or the like cuts through the still moist mortar layer and the glass fiber reinforcement, possibly also the core element 101, in the region of the joints or at selected intervals. Finally, the core element 101 and the applied reinforced mortar layer 103 are dried and hardened in a heating oven 216. The reinforced mortar layer is thus firmly anchored on the core element 101. The core element 101 coated on one side can already be used in this form. However, it is usually coated on both sides. For this purpose, it is brought back to the start of the roller conveyor 201 and turned so that now the uncoated web side lies above and the same procedure can be carried out as has already been described.

Various mixtures of cement, water, and plastics (known as polymer concrete), which are known per se, are suitable as mortar material. These mixture recipes are known per se. The thickness of the core is relatively uncritical. It can be between a few millimeters and a few centimeters. As already described, this depends on the respective need. The mortar layer is usually applied as sparingly as possible. Sufficient embedding of the glass fiber fabric or fleece 102 must be ensured. Instead of the glass fiber fabric or nonwoven, other materials, for example aramid fabric, polyester fleece, metallic fabric or the like can also be used if they provide the required reinforcement properties. In the same way, a foam core 101 'can be provided with at least one reinforced mortar layer 103'. It is also possible to coat or impregnate the individual mineral fiber elements. By pressing these fibers together, a composite panel 110 is formed without any other coating.

Once the composite panel section 110 has been produced, it is placed in accordance with FIG. 1 on a further roller conveyor (not shown) on which it is conveyed on. Using a combined milling and cutting tool (not shown), as shown in FIG. 2, two double strips 104, 105 with a width B1 or B2 are cut from the composite plate 110. Instead of two double strips, three and possibly further strips could be cut and milled at the same time. The widths to which the double strips 104 and 105 are cut, milled or pressed depends on the respective operating conditions.

A V-shaped groove 106 is also milled into the double strip 104 and has an opening angle of 90 °. Care is taken to ensure that the milling chips are removed from the V-groove 106 by suction and blowing off. An identical groove can also be introduced into the strips 104 and 105 instead of the separation or else into the double strip 105.

After the composite plate 110 has passed completely through the pressing, milling and cutting tools, it arrives at an optical sensing station 107. This sensing station issues a signal to a corresponding control device, so that when the composite plate section has passed the full length in each case, the Milling and cutting tools are disengaged.

Now a controllable stop 128 is folded up out of the conveying plane, which breaks the double strip 104 in the groove 106. The groove 106 has been introduced into the core element 101 or the foam core 101 'to such an extent that it completely pierces it, but does not cut through the reinforced mortar layer 103' located below or in front of it. This makes it possible for the groove tip bridging reinforcement to be retained and thus to form a smooth, continuous and stable outer surface. The one composite panel strip 109 is then at a right angle to the other composite panel strip 119, so that an L configuration according to FIG. 3 results.

Immediately before the installation in the L configuration or in this configuration, a liquid hot glue is introduced into the space between the inner sides of the groove 106 with the aid of a mouthpiece 111 with an outlet nozzle. The hot glue hardens under cooling. During this cooling, it is additionally cooled by additional cooling nozzles 112, which are made from an accompanying pipe 113, the ambient air is supplied, and which is provided with individual, distributed over the length cooling nozzles, cooled. After the cooling section has expired, the hot glue has hardened and the semi-finished product is ready for use. The reinforcement 102 bridges the groove tip and forms an additional firm connection between the two composite plate strips 109 and 119.

A closed hollow profile can be produced from the semi-finished product thus produced by gluing together two such semi-finished products. Tube boxes can also be made by gluing a single arm. It should not be ruled out that instead of a bend, other bends at an angle other than 90 ° can also be carried out with corresponding further milling and stop devices. This provides the option of also producing angled wall and anti-glare configurations from continuous semi-finished products made of composite panels.

Claims (10)

1. A method of producing angular semifinished products from boards of composite material comprising a relatively easily-worked core element (101), more particularly a foam core (101'), and at least one reinforcement of fibres applied to one of the flat sides, more particularly glass fibre fabric or matting (102) embedded in a hardened mortar layer (103), the processing steps being as follows:

   a) a rectangular portion (110) of a composite board having a width ( $\text{B1 + B2 + ...}$

   

   ) is cut by a combined milling and cutting tool movable relative to the longitudinal extension of the composite-board portion into double strips (104, 105) having widths (B1, B2, ...), and simultaneously a V-shaped groove (106) is formed in at least one of the double strips, the groove having a depth which avoids the fibre reinforcement, and a strip of composite board (109, 119) being formed on each side of the groove (106),

   b) next the double strip (104) formed with the V-shaped groove (106) is broken along the groove (106) while retaining the reinforcement (102) which bridges the bottom of the groove, and the two strips of board (101, 119) are erected to form an L shape, the insides of the groove becoming mitre surfaces,

   c) a liquid heat-sealing adhesive is introduced into the space between the inner sides of the groove, and

   d) the adhesive is left to cool and the finished angular semifinished product is taken out.
2. A method according to claim 1, characterised in that the V-shaped groove (106) has an opening angle of 90°.
3. A method according to claim 1 or 2, characterised in that the composite board portion (110) is conveyed along a conveying section under stationary milling and sawing tools.
4. A method according to any of claims 1 to 3, characterised in that cooling air is blown on to the angular semifinished blanks along a conveying section after the adhesive has been applied.
5. A method according to any of the preceding claims, characterised in that for the purpose of erecting to the L-shape, an actuatable abutment (128) can be swung out of the conveying plane.
6. A method according to claim 5, characterised in that the abutment (128) co-operates with a sensing device (107) which triggers the erection of the abutment (128) after the composite board portion (110) has run through the milling and sawing device.
7. A method according to any of the preceding claims, characterised in that the milling and/or sawing device is adjustable across the width of the composite board portion (110).
8. A method according to any of claims 1 to 7, chracterised in that the semifinished product is used for producing tubular boxes and closed hollow profiles.
9. A method according to any of claims 1 to 8, characterised in that the core element (101) is made of compacted fibres including wool (122'), balls, chips, strips, parts or the like of organic and/or inorganic materials, e.g. mineral fibres (122).
10. A method according to any of claims 1 to 9, characterised in that the core element made of compacted fibres, including wool (102'), balls, chips, strips, parts or the like of organic and/or inorganic substances, e.g. mineral fibres (122), is so coated with extruder foam (108, 121) that the fibres, balls, chips, strips, parts or the like of organic and/or inorganic materials are interspersed in the extruder foam (108, 121).

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